Electrical receptacle assembly with outward-biasing faceplate

ABSTRACT

A faceplate assembly may include a faceplate having an opening configured to receive an electrical device insert, and an adapter that is disposed between the faceplate and a structure. The adapter may abut a surface of the structure. The faceplate assembly may include one or more biasing members that may be configured to bias the faceplate outward relative to the structure. A first biasing member may include one or more resilient fingers. The fingers may be configured to abut a yoke that is installed in the structure (e.g., attached within an opening of the structure). A second biasing member may include a resilient spacer that is configured to be disposed between the faceplate and the adapter. The one or more biasing members may apply forces against the faceplate that may cause the faceplate to be biased outward relative to the surface of the structure.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional U.S. patentapplication No. 62/316,844, filed Apr. 1, 2016, the disclosure of whichis incorporated herein by reference in its entirety.

BACKGROUND

In accordance with an electrical receptacle assembly installation, anelectrical receptacle may be fixed to a structure, such as a yokeinstalled in a wall opening, such that the electrical receptacleprotrudes outward beyond a surface of the wall. In such an installation,it may be desirable to attach a faceplate to the electrical receptacle,such that the faceplate appears to “float” relative to the wall.However, anomalies in the surface of the wall and/or other structuralcomplications may hinder the alignment of corresponding surfaces of theelectrical receptacle and the faceplate, and further may inhibitmaintenance of the alignment of such surfaces.

SUMMARY

As described herein, an example faceplate assembly may include afaceplate that defines an opening that is configured to receive anelectrical device insert. The faceplate assembly may include an adapterthat is configured to be disposed between the faceplate and a structureto which the faceplate assembly is installed, such as an interior wall.The adapter may be configured to at least partially surround a portionof the electrical device insert. The adapter may be further configuredto abut a surface of the structure.

The faceplate assembly may include one or more biasing members that maybe configured to bias the faceplate outward relative to the structure,such that the faceplate is spaced from a surface of the structure. Afirst biasing member may include one or more resilient fingers that maybe configured to bias the faceplate against the electrical deviceinsert. The fingers may be configured to abut a yoke that is installedin the structure (e.g., attached within an opening of the structure),and thereby to bias the faceplate against the electrical device insert.Each finger may include a cantilevered beam defined at a location alonga perimeter of the opening in the faceplate. Each finger may beangularly offset inward relative to an outer surface of the faceplate.

A second biasing member may include a resilient spacer that isconfigured to be disposed between the faceplate and the adapter. Thespacer may be configured to abut an inner surface of the faceplate. Thespacer may bias the adapter against the surface of the structure, andmay further bias the faceplate against the electrical device insert.

The one or more biasing members may apply biasing forces against aninner surface of the faceplate. These forces may cause the faceplate tobe biased outward relative to the surface of the structure, for instancesuch that the faceplate abuts the electrical device insert. This mayallow the faceplate assembly to compensate for one or more anomalies ofthe surface of the structure, while maintaining parallel alignmentbetween corresponding outer surfaces of the faceplate and the electricaldevice insert.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example electrical receptacleassembly that includes an outward-biased faceplate assembly.

FIG. 2 is an exploded view of the example electrical receptacle assemblyillustrated in FIG. 1.

FIG. 3A is a perspective view of the front of a faceplate of the exampleelectrical receptacle assembly illustrated in FIG. 1.

FIG. 3B is a front view of the faceplate of the example electricalreceptacle assembly illustrated in FIG. 1.

FIG. 3C is a rear view of the faceplate of the example electricalreceptacle assembly illustrated in FIG. 1.

FIG. 3D is a perspective view of the rear of the faceplate of theexample electrical receptacle assembly illustrated in FIG. 1.

FIGS. 3E-3H are left, top, right, and bottom views, respectively, of thefaceplate of the example electrical receptacle assembly illustrated inFIG. 1.

FIG. 4 is a side section view of the example electrical receptacleassembly illustrated in FIG. 1.

FIG. 5 is an exploded view of another example electrical receptacleassembly.

FIG. 6 is a side section view of the example electrical receptacleassembly illustrated in FIG. 5.

DETAILED DESCRIPTION

FIGS. 1 and 2 depict an example electrical receptacle assembly 100. Asshown, the electrical receptacle assembly 100 may include an examplefaceplate assembly 110, a yoke 120, and an electrical device insert 130.The electrical receptacle assembly 100 may be installed in a structure,such as a wall 140 or other structure. Wall 140 may be, for example, aninterior wall of a building. The structure may define a surface whichmay be abutted by one or more components of the electrical receptacleassembly 100. For example, as shown, the wall 140 defines a surface 142.

The yoke 120 may be installed in the structure. For example, theillustrated wall 140 defines an opening 144 into which the yoke 120 maybe installed. The yoke 120 may define an opening 122 that is configuredto at least partially receive the electrical device insert 130. The yoke120 may further define a collar 124 that is sized larger than theopening 144 in the wall 140, such that one or more portions of thecollar 124 abut the surface 142 of the wall 140 when the yoke 120 isinstalled in the opening 144.

The electrical device insert 130 may define a cavity 132 that isconfigured to receive one or more electrical devices, such as plugmodules (not shown). For example, as shown, the cavity 132 of theelectrical device insert 130 may be configured to receive one or moretypes of electrical receptacle plug modules. This may allow theelectrical receptacle assembly 100 to be installed and used inelectrical systems having different plug type requirements. A plugmodule installed in the cavity 132 of the electrical device insert 130may be electrically connected to a source of power, such as alternatingcurrent (AC) power source, for example via the yoke 120.

The electrical device insert 130 may be configured to attach to the yoke120. For example, the yoke 120 may include a strap 126 to which theelectrical device insert 130 may be attached, for instance using afastener such as a screw (not shown). When the electrical device insert130 is attached to the yoke 120, at least a portion of the electricaldevice insert 130 may protrude beyond the surface 142 of the wall 140,for example as shown in FIGS. 1 and 4. For example, as shown, when theelectrical device insert 130 is attached to the yoke 120, an outersurface 134 of the electrical device insert 130 may be spaced outwardfrom the surface 142 of the wall 140. The outer surface 134 mayalternatively be referred to as a front surface of the electrical deviceinsert 130.

As shown in FIG. 2, the example faceplate assembly 110 may include afaceplate 150, an adapter 170, and may optionally include a spacer 180.The spacer 180 may be configured as a biasing member, as describedelsewhere herein. One or more components of the faceplate assembly 110may be configured to cause the faceplate 150 to be biased outwardrelative to a structure to which the electrical receptacle assembly 100is installed, for instance the wall 140, such that the faceplate 150 isspaced from the surface 142 of the wall 140. In this regard, thefaceplate 150 may be referred to as an outward-biasing or outward-biasedfaceplate. Outward bias of the faceplate 150 relative to a structure mayallow one or more portions of the faceplate 150 to align with one ormore other components of the electrical receptacle assembly 100, such asthe electrical device insert 130.

The faceplate 150 may be referred to as an electrical receptaclefaceplate, and may be made of any suitable material, such as plastic. Asshown, the faceplate 150 includes a plate 152 that defines an outersurface 154 of the faceplate 150 and an opposed inner surface 156 of thefaceplate. The outer surface 154 may alternatively be referred to as afront surface of the faceplate 150. The faceplate 150 may define anopening 158 that extends through the plate 152. The opening 158 may beconfigured to at least partially receive the electrical device insert130. For example, as shown, the faceplate 150 includes inner walls 160that extend around, and bound, a perimeter of the opening 158. The innerwalls 160 extend rearward from the inner surface 156 of the plate 152.In accordance with the example faceplate 150, the opening 158 is square,defining four inner corners 159. However, it should be appreciated thatthe faceplate 150 is not limited to the illustrated square opening, andthat the geometry of the opening may be otherwise configured.

The faceplate 150 may be configured to abut the electrical device insert130 when the faceplate 150 is biased outward relative to the wall 140.For instance, the faceplate 150 may define one or more abutment surfacesthat are configured to abut corresponding portions of the electricaldevice insert 130 such that the outer surface 134 of the electricaldevice insert 130 is proud relative to, or substantially flush with, theouter surface 154 of the faceplate 150.

For example, as shown, the faceplate 150 may define one or more ledges161 that are spaced inward from the outer surface 154 of the faceplate150. The ledges 161 may define respective abutment surfaces that areconfigured to abut the electrical device insert 130 when the faceplate150 is biased outward relative to the wall 140. The illustratedfaceplate 150 includes four ledges 161 defined at corresponding innercorners 159 of the opening 158. As shown, each ledge 161 may define oneor more abutment surfaces 162, such as a pair of abutment surfaces 162,which are raised relative to outward-facing surfaces of thecorresponding ledges 161.

As shown, the inner walls 160 may extend from the inner surface 156 ofthe faceplate 150 to the ledges 161. It should be appreciated that thefaceplate 150 is not limited to the illustrated number or arrangement ofledges 161 and/or abutment surfaces 162, and more generally is notlimited to the illustrated configuration of abutment surfaces 162. Theabutment surfaces 162 may be spaced from the outer surface 154 of thefaceplate 150 such that, when the faceplate 150 is biased outward suchthat one or more of the abutment surfaces 162 abut correspondingportions of the electrical device insert 130, the outer surface 134 ofthe electrical device insert 130 may align proud of, or may alignsubstantially flush with, the outer surface 154 of the faceplate 150.The illustrated faceplate further includes outer walls 164 that extendrearward from the inner surface 156 of the plate 152 along an outerperimeter of the plate 152.

The adapter 170 may be configured to be disposed between the faceplate150 and a structure to which the electrical receptacle assembly 100 isinstalled, such as the wall 140. The adapter 170 may be made of anysuitable material, such as plastic. As shown, the adapter 170 includesouter walls 172. The outer walls 172 may define an outer perimeter ofthe adapter 170. The adapter 170 may be configured such that a rearsurface 174 defined by the outer walls 172 abuts the surface 142 of thewall 140 when the electrical receptacle assembly 100 is installed in thewall 140. The outer walls 172 may be of sufficient height (e.g., definedalong a direction that extends perpendicular to the rear surface 174)such that the outer walls 172 may at least partially surround a portionof the electrical device insert 130 when the electrical receptacleassembly 100 is installed, for instance as shown in FIG. 4.

The outer walls 172 may be of sufficient length (e.g., defined betweencorners where the outer walls 172 intersect) such that, when theelectrical receptacle assembly 100 is installed, the walls 172 surroundbut do not contact the yoke 120 and the inner walls 160 of the faceplate150, and the outer walls 172 are recessed relative to the outer walls164 of the faceplate 150. Stated differently, the outer walls 172 maybound an area that is larger than respective areas bound by the collar124 of the yoke 120 and the inner walls 160 of the faceplate, but issmaller than an area bound by the outer walls 164 of the faceplate 150.In this regard, the inner walls 160 of the faceplate 150 fit within anarea bound by the outer walls 172 of the adapter 170, and the outerwalls 172 of the adapter 170 fit within an area bound by the outer walls164 of the faceplate 150. As shown, the outer walls 172 are of equallength, such that the adapter 170 defines a square shape. However, itshould be appreciated that the adapter 170 is not limited to theillustrated square-shaped outer perimeter. The adapter 170 may beconfigured to receive at least a portion of the spacer 180. For example,as shown, the adapter 170 includes a ledge 176 that extends around aninner perimeter of the outer walls 172. The spacer 180 may be disposedinto the adapter 170 such that the spacer abuts the ledge 176, forexample when the electrical receptacle assembly 100 is in an installedconfiguration (e.g., as shown in FIG. 1).

The faceplate assembly 110 may include one or more biasing members thatmay be configured to cause the faceplate 150 to be biased outwardrelative to the wall 140, such that the faceplate 150 is spaced from thesurface 142 of the wall 140. The one or more biasing members may causethe faceplate 150 to abut the electrical device insert 130.

For example, as shown, the faceplate 150 may include one or moreresilient fingers 166 that are configured to abut and deflect againstthe collar 124 of the yoke 120, thereby causing one or more of theabutment surfaces 162 of the faceplate 150 to be biased againstcorresponding portions of the electrical device insert 130. As shown,the faceplate 150 includes a plurality of fingers 166 that may referredto as first biasing members of the faceplate assembly 110.

In accordance with the illustrated faceplate 150, each finger 166 isdefined by a beam that is cantilevered to one of the ledges 161, andthat extends from a corresponding inner corner 159 along a perimeter ofthe opening 158. As shown, each finger 166 is angularly offset inwardlyrelative to the outer surface 154 of the faceplate 150, for example asshown in FIGS. 3E-3H. Further in accordance with the illustratedfaceplate 150, two fingers 166 extend from each ledge 161, at rightangles to each other, and parallel to corresponding ones of the innerwalls 160 of the faceplate 150.

When the faceplate assembly 110 is installed in the wall 140, one ormore of the plurality of fingers 166 may resiliently deflect against theyoke 120, which may cause the one or more fingers 166 to apply biasingforces against the yoke 120. These forces may cause the faceplate 150 tobe biased outward relative to the surface 142 of the wall 140, forinstance such that one or more abutment surfaces 162 of the faceplate150 abut corresponding portions of the electrical device insert 130.This may operate to securely hold the faceplate 150 in position againstthe electrical device insert 130, and/or may maintain parallel alignmentbetween the outer surface 154 of the faceplate and the outer surface 134of the electrical device insert 130.

The faceplate assembly 110 may include one or more additional biasingmembers. For example, the faceplate assembly 110 may optionally includea spacer 180 that may be referred to as a second biasing member of thefaceplate assembly 110. The illustrated spacer 180 includes walls 182that may define an outer perimeter of the spacer 180. As shown, thewalls 182 are of equal length (e.g., defined between corners where theouter walls 182 intersect), such that the spacer 180 defines a squareshape. However, it should be appreciated that the spacer 180 is notlimited to the illustrated square-shaped outer perimeter. The walls 182of the illustrated spacer 180 define respective lengths such that thewalls 182 of the spacer 180 may fit within the outer walls 172 of theadapter 170.

The spacer 180 may be made of a resilient material, such as compressiblefoam. In this regard, the spacer 180 may be configured to be compressedbetween the adapter 170 and the faceplate 150. The walls 182 of thespacer 180 may define an inner abutment surface 184 that is configuredto abut the ledge 176 of the adapter 170, and may define an opposedouter abutment surface 186 that is configured to abut the inner surface156 of the faceplate 150. One or both of the inner abutment surface 184and the outer abutment surface 186 may be configured to adhere to theadapter 170 and to the inner surface 156 of the faceplate 150,respectively, for example using double-sided adhesive. The walls 182 ofthe illustrated spacer 180 are of a height (e.g., defined along adirection that extends perpendicular to the inner and outer abutmentsurfaces 184, 186) such that the walls 182 protrude outward beyond theouter walls 172 of the adapter 170 when the inner abutment surface 184abuts the ledge 176 of the adapter 170. In this regard, when the spacer180 is seated in the adapter 170, the outer abutment surface 186 isspaced outwardly from corresponding edge surfaces of the outer walls 172of the adapter 170.

When compressed between the adapter 170 and the faceplate 150, with therear surface 174 of the outer walls 172 of the adapter 170 abutting thesurface 142 of the wall 140, the spacer 180 may apply biasing forcesagainst the ledge 176 and the inner surface 156 of the faceplate 150.These forces may cause the faceplate 150 to be biased outward relativeto the surface 142 of the wall 140, for instance such that one or moreof the abutment surfaces 162 of the faceplate 150 abut correspondingportions of the electrical device insert 130, and may further cause therear surface 174 of the adapter 170 to be biased against the surface 142of the wall 140. The biasing forces may allow the faceplate assembly 110to compensate for one or more anomalies of the surface 142 of the wall140, while maintaining parallel alignment between the outer surface 154of the faceplate and the outer surface 134 of the electrical deviceinsert 130.

FIGS. 5 and 6 depict another example electrical receptacle assembly 200.As shown, the electrical receptacle assembly 200 may include an examplefaceplate assembly 210, a yoke 120, and an electrical device insert 130.The electrical receptacle assembly 200 may be installed in a structure,such as the wall 140 or other structure.

As shown in FIG. 5, the example faceplate assembly 210 may include afaceplate 250, an adapter 270, and one or more biasing members such as aspacer 280. One or more components of the faceplate assembly 210 may beconfigured to cause the faceplate 250 to be biased outward relative to astructure to which the electrical receptacle assembly 200 is installed,for instance the wall 140, such that the faceplate 250 is spaced fromthe surface 142 of the wall 140. In this regard, the faceplate 250 maybe referred to as an outward-biasing or outward-biased faceplate.Outward bias of the faceplate 250 relative to a structure may allow oneor more portions of the faceplate 250 to align with one or more othercomponents of the electrical receptacle assembly 200, such as theelectrical device insert 130.

The faceplate 250 may be referred to as an electrical receptaclefaceplate, and may be made of any suitable material, such as plastic.The faceplate 250 may be constructed similarly to the faceplate 150, forexample omitting the fingers 166. For example, as shown, the faceplate250 may define one or more ledges 261 that are spaced inward from anouter surface 254 of the faceplate 250. The ledges 261 may definerespective abutment surfaces that are configured to abut the electricaldevice insert 130 when the faceplate 250 is biased outward relative tothe wall 140. The illustrated faceplate 250 includes four ledges 261(only one is shown) defined at corresponding inner corners 259 of anopening 258 that extends through the faceplate 250. Each ledge 261 maydefine one or more abutment surfaces 262, such as a pair of abutmentsurfaces 262, which are raised relative to outward-facing surfaces ofthe corresponding ledges 261.

The faceplate 250 may be configured to abut the electrical device insert130 when the faceplate 250 is biased outward relative to the wall 140.For instance, the abutment surfaces 262 may be spaced from the outersurface 254 of the faceplate 250 such that, when the faceplate 250 isbiased outward such that one or more of the abutment surfaces 262 abutcorresponding portions of the electrical device insert 130, the outersurface 134 of the electrical device insert 130 may align proud of, ormay align substantially flush with, an outer surface 254 of thefaceplate 250.

The adapter 270 may be constructed similarly to the adapter 170, and maybe configured to be disposed between the faceplate 250 and a structureto which the electrical receptacle assembly 200 is installed, such asthe wall 140. The spacer 280 may be constructed similarly to the spacer180, and may be configured to cause the faceplate 250 to be biasedoutward relative to the wall 140, such that the faceplate 250 is spacedfrom the surface 142 of the wall 140. The spacer 280 may be referred toas a biasing member of the faceplate assembly 210.

When compressed between the adapter 270 and the faceplate 250, thespacer 280 may apply biasing forces against the adapter 270 and thefaceplate 250. These biasing forces may cause the faceplate 250 to bebiased outward relative to the surface 142 of the wall 140, for instancesuch that one or more of the abutment surfaces 262 of the faceplate 250abut corresponding portions of the electrical device insert 130. Thebiasing forces may further cause a rear surface 274 of the adapter 270to be biased against the surface 142 of the wall 140. This may allow thefaceplate assembly 210 to compensate for one or more anomalies of thesurface 142 of the wall 140, while maintaining parallel alignmentbetween the outer surface 254 of the faceplate and the outer surface 134of the electrical device insert 130.

It should be appreciated that faceplate assemblies, such as the examplefaceplate assemblies 110 and 210 illustrated and described herein, arenot limited to use with other components of the illustrated electricalreceptacle assemblies 100, 200. For example, as shown, the faceplateassemblies 110 and 210 are configured to cooperate with the illustratedyoke 120 and electrical device insert 130 to bias the respectivefaceplates 150, 250 outward relative to structure. However, one or morecomponents of the respective faceplate assemblies may be alternativelyconfigured to cooperate with the yoke of a different electrical device,such as the yoke of a standard single pole single throw (SPST)maintained switch for example, to bias the faceplate outward relative tostructure.

1. A faceplate assembly comprising: a faceplate that defines an openingthat is configured to receive an electrical device insert; a biasingmember that is configured to bias the faceplate outward relative to astructure, such that the faceplate is spaced from a surface of thestructure; and an adapter that is configured to be disposed between thefaceplate and the structure, such that the adapter at least partiallysurrounds a portion of the electrical device insert, the adapter furtherconfigured to abut the surface of the structure.
 2. The faceplateassembly of claim 1, wherein the biasing member comprises a plurality ofresilient fingers that are configured to bias the faceplate against theelectrical device insert.
 3. The faceplate assembly of claim 2, whereinthe faceplate further defines at least one ledge that is spaced inwardfrom an outer surface of the faceplate, the at least one ledgeconfigured to abut the electrical device insert when the faceplate isbiased outward relative to the structure.
 4. The faceplate assembly ofclaim 3, wherein the at least one ledge comprises four ledges, andwherein each ledge is defined at a corresponding corner of the opening.5. The faceplate assembly of claim 4, wherein the faceplate furtherdefines inner walls that extend around a perimeter of the opening, andthat extend rearward from an inner surface of the faceplate to theledges.
 6. The faceplate assembly of claim 5, wherein the faceplatefurther defines outer walls that extend rearward from the inner surfaceof the faceplate along an outer perimeter of the faceplate.
 7. Thefaceplate assembly of claim 6, wherein the adapter comprises walls thatdefine an outer perimeter of the adapter, wherein the inner walls of thefaceplate fit within an area bound by the walls of the adapter, andwherein the walls of the adapter fit within an area bound by the outerwalls of the faceplate.
 8. The faceplate assembly of claim 4, whereinthe ledges are spaced inward from the outer surface of the faceplatesuch that, when one or more of the ledges abut the electrical deviceinsert, a front surface of the electrical device insert is proud orflush relative to the outer surface of the faceplate.
 9. The faceplateassembly of claim 4, wherein the plurality of fingers comprises eightfingers, and wherein two fingers extend from each ledge.
 10. Thefaceplate assembly of claim 2, further comprising a second biasingmember that is configured to bias the adapter relative to the structure.11. The faceplate assembly of claim 10, wherein the second biasingmember comprises a resilient spacer that is configured to be disposedbetween the faceplate and the adapter, and to abut an inner surface ofthe faceplate, thereby biasing the adapter against the surface.
 12. Thefaceplate assembly of claim 11, wherein the adapter is configured toreceive the spacer.
 13. The faceplate assembly of claim 12, wherein thespacer defines an inner abutment surface that is configured to abut theadapter, and an opposed outer abutment surface that is configured toabut the inner surface of the faceplate.
 14. The faceplate assembly ofclaim 13, wherein the inner and outer abutment surfaces are configuredto adhere to the adapter and to the inner surface of the faceplate,respectively.
 15. The faceplate assembly of claim 11, wherein the spacercomprises compressible foam.
 16. The faceplate assembly of claim 2,wherein the plurality of fingers are configured to abut a yoke that isinstalled in the structure, and thereby to bias the faceplate againstthe electrical device insert.
 17. The faceplate assembly of claim 2,wherein each finger comprises a cantilevered beam defined at a locationalong a perimeter of the opening, and wherein each finger is angularlyoffset inward relative to an outer surface of the faceplate.
 18. Afaceplate that is configured to bias outward relative to a structure,the faceplate comprising: a plate that defines a front surface and anopening that extends through the plate, the opening configured toreceive an electrical device insert; outer walls that extend rearwardfrom the plate along an outer perimeter of the plate; and a biasingmember that is configured to bias the faceplate outward relative to thestructure, such that the faceplate is spaced from a surface of thestructure.
 19. The faceplate of claim 18, wherein the biasing membercomprises a plurality of resilient fingers that are configured to biasthe faceplate against the electrical device insert.
 20. The faceplate ofclaim 19, wherein the plate defines at least one ledge that is spacedinward from the front surface of the plate, the at least one ledgeconfigured to abut the electrical device insert when the faceplate isbiased outward relative to the structure.
 21. The faceplate of claim 20,wherein the at least one ledge comprises four ledges, and wherein eachledge is defined at a corresponding corner of the opening.
 22. Thefaceplate of claim 21, wherein the ledges are spaced inward from thefront surface of the plate such that, when one or more of the ledgesabut the electrical device insert, an outer surface of the electricaldevice insert is proud or flush relative to the front surface of theplate.
 23. The faceplate of claim 21, wherein the plurality of fingerscomprises eight fingers, and wherein two fingers extend from each ledge.24. The faceplate of claim 21, wherein the plate further defines innerwalls that extend around a perimeter of the opening, and that extendrearward from the plate to the ledges.
 25. The faceplate of claim 19,wherein the plurality of fingers are configured to abut a yoke that isinstalled in the structure, thereby biasing the faceplate against theelectrical device insert.
 26. The faceplate of claim 19, wherein eachfinger comprises a cantilevered beam defined at a location along aperimeter of the opening, and wherein each finger is angularly offsetinward relative to the front surface of the plate.